Bacharach, Inc.

625 Alpha Drive, Pittsburgh, PA 15238-2878

Phone: (412) 963-2000 FAX (412) 963-2091 Web: www.bacharach-inc.com
Registered Trademark
of Bacharach, Inc.
Printed in U.S.A.
INSTRUCTION 67-9268
Technician Series Model
7.5 & 10 HP Fuel Injection Pump
Calibrating Stands
Installation/Operation/Maintenance
Rev. 4 April 1999
Technician 7.5 & 10 Contents
Instruction 67-9268 Bacharach, Inc. Page i
TABI OI CONTNTS
Puge
1.0 INTRO\CTION............................................................................................................................ 1-1
1.1 Specifications ........................................................................................................................... 1-1
1.1.1 General ...................................................................................................................... 1-1
1.1.2 Main Drive ................................................................................................................1-1
1.1.3 Calibration Fluid Supply System ............................................................................ 1-1
1.1.4 Instrumentation ....................................................................................................... 1-2
1.2 Optional Accessories ................................................................................................................ 1-2
2.0 INSTAIIATION ............................................................................................................................. 2-1
2.1 Stand Preparation and Hook-up ............................................................................................. 2-1
2.1.1 Leveling..................................................................................................................... 2-1
2.1.2 Electrical Hook-Up (Wiring) .................................................................................... 2-1
2.3 Filling Reservoir ...................................................................................................................... 2-2
2.4 Basic Accessories...................................................................................................................... 2-2
3.0 OPRATION ................................................................................................................................... 3-1
3.1 Control & Light Functions ...................................................................................................... 3-1
3.1.1 Console Panel (Figure 3-1) ....................................................................................... 3-1
3.1.2 Front Panel (Figure 3-2) .......................................................................................... 3-3
3.1.3 Side Panels (Figure 3-3) ........................................................................................... 3-3
3.2 Tachometer / Counter Assembly ............................................................................................. 3-3
3.3 Calibration Fluid System ........................................................................................................ 3-3
3.3.1 Calibration Fluid Temperature Control (TEMP. ADJ.) .......................................... 3-4
3.3.2 Front Panel Connections (Figure 3-2) ..................................................................... 3-4
3.3.3 Waste Tank ............................................................................................................... 3-5
3.4 Water Cooling System ............................................................................................................. 3-5
3.5 Graduates ................................................................................................................................. 3-5
3.5.1 Reading the Graduates (Figure 3-5) ........................................................................ 3-5
3.5.2 Draining the Graduates (Figure 3-6) ...................................................................... 3-6
3.6 Accumulator Arm Assembly .................................................................................................... 3-6
3.7 Flexible Anti-Backlash Coupling ............................................................................................ 3-6
3.8 Correct Use of Alignment Gauge ............................................................................................ 3-6
3.9 Typical Operating Sequence.................................................................................................... 3-7
3.10 Shutdown Procedure ............................................................................................................... 3-8
3.11 Mounting Injection Pumps and Test Injectors ....................................................................... 3-8
Page ii Bacharach, Inc. Instruction 67-9268
Contents Technician 7.5 & 10
4.0 MAINTNANC & TRO\BISHOOTING ............................................................................... 4-1
4.1 Maintenance............................................................................................................................. 4-1
4.1.1 Belt Tensioning ......................................................................................................... 4-1
4.1.2 Lubrication (Figure 4-1) ........................................................................................... 4-1
4.1.3 Calibration Fluid ...................................................................................................... 4-1
4.1.4 Graduates (Care/Cleaning) ...................................................................................... 4-2
4.1.5 Adjustment of Magnetic Pickup .............................................................................. 4-2
4.1.6 Tach/Counter Replacement ...................................................................................... 4-3
4.1.7 Removal of Flexible Coupling .................................................................................. 4-3
4.1.8 Flexible Coupling Installation ................................................................................. 4-4
4.1.9 Motor Starter Overload Relay Adjustment ............................................................. 4-6
4.2 Troubleshooting ....................................................................................................................... 4-7
4.2.1 Electrical ................................................................................................................... 4-7
4.2.2 Mechanical ................................................................................................................ 4-8
5.0 PARTS IISTS.................................................................................................................................. 5-1
5.1 Belts, Filters, Etc. .................................................................................................................... 5-1
5.2 Electrical Components............................................................................................................. 5-1
5.3 Instruments ............................................................................................................................. 5-2
5.4 Miscellaneous Parts ................................................................................................................. 5-2
5.5 Optional Accessories ................................................................................................................ 5-2
APPNIX A P\MP MO\NTING IAGRAMS ............................................................................... A-1
APPNIX B - INJCTOR ACC\M\IATOR ACCSSORIS ....................................................... B-1
Technician 7.5 & 10 Contents
Instruction 67-9268 Bacharach, Inc. Page iii
WARNINGS AND CAUTIONS
WARNINGS
DO NOT attempt to make any adjustments or repairs to the electrical compo-
nents of the Technician Stand without first disconnecting the main power line
at the wall. Many connections within the Stand carry lethal voltages. Any
work done to the electrical system should be performed by qualified personnel.
DO NOT operate the Technician Stand with the flexible coupling mounted
and no injection pump attached, this is extremely hazardous and will perma-
nently damage the coupling.
Use the flexible coupling guard at all times.
DO NOT depress the run button without being aware of the speed control
selection and setting.
Use of any adapters and/or couplings, not approved by Bacharach, Inc., to
mount injection pumps to the Technician Stand may be dangerous and could
void the warranty. Bacharach approved couplings and mounting adapters are
designed specifically to work with both the Technician 7.5 and 10.
CA\TIONS
DO NOT apply electrical power or attempt to operate the Technician Stand
until all steps in Section 2 are completed.
To maintain a free flow of cooling water, do not install a valve or any restric-
tion in the water drain hose.
To prevent calibration fluid heater burn-out, make certain that the Calibra-
tion Fluid HEAT switch is OFF when power is applied to the Technician
Stand with the fuel reservoir empty.
Make certain that there is 1" clearance between the degree wheel and the
coupling guard. Failure to have sufficient clearance could damage the degree
wheel (Figure 4-11).
The flexible coupling rear flange lock nuts must be checked for tightness
periodically (at least once per month).
Periodically check all hoses and connections to insure safe operation of the
Technician Stand.
DO NOT leave the Technician Stand unattended while the drive system is
rotating.
Page iv Bacharach, Inc. Instruction 67-9268
Contents Technician 7.5 & 10
NOTS
Technician 7.5 & 10 Introduction
Instruction 67-9268 Bacharach, Inc. Page 1-1
1.0 INTRODUCTION
The Bacharach Technician Series Model 7.5 and
10HP Fuel Injection Pump Calibrating Stands are
designed for testing and calibrating light to me-
dium duty diesel fuel injection pumps used on
engines employed in the construction, automotive,
power generation, and farm equipment fields. Its
low cost, compact design and simple operation
make the Technician Stand an ideal choice for a
new or expanding diesel fuel injection shop.
The anti-backlash, flexible, pump coupling is
driven by an AC motor coupled to a flywheel.
Controls for pump rotation selection, speed set-
tings, run, and stop are located on the console
panel. The speed setting control (potentiometer)
can vary the drive speed between 70 and
3500RPM (nominal).
The components located on the Technician Stands
front panel are: the digital tachometer/stroke
counter, Calibration Fluid Supply Temperature,
and the Calibration Fluid Vacuum/Pressure
gauges. The gauges have English and metric
scales. The calibration fluid collection and measur-
ing system consists of a swiveling single block
accumulator, attached to either side of the Stand,
feeding into 8 graduates of 160cc capacity. The
calibration fluid reservoir has a spout with a built
in dipstick for measuring fluid level.
1.1 Specifications
1.1.1 General
(a) Dimensions Width - 28" (.71 m)
Height - 68" (1.73 m)
Depth - 40" (1.02 m)
Weight Dry - 1200 lbs (545 kg)
(b) Electrical requirements:
Refer to Table 2-2.
(c) Water Consumption: Cold tap at approxi-
mately 1.2 gpm (4.5 liters/min.), gravity
drain.
1.1.2 Main Drive
(a) AC adjustable frequency electric motor.
(b) Rotary dial speed control adjustable from
703500 RPM.
(c) Flywheel moment of inertia: WR
2
= 1145 lb
in
2
(0.336 kgm
2
).
(d) Backlash free flexible coupling, laminated
disc design (Light Duty).
1.1.3 Calibration Fluid Supply System
(a) Fluid is either supplied under pressure to
the injection pump or drawn from the
reservoir under suction by the supply pump
that is mounted on the injection pump
under test.
(b) Thermostatically controlled calibration
fluid reservoir [capacity: 13 gallons (50li-
ters)] complete with four 500 watt heaters,
cooling coil, temperature sensor, overheat
safety switch with solid-state temperature
controller. Calibration Fluid temperature
controlled to 2 F under normal operating
conditions.
(c) Large 10 micron submersed reservoir filter.
(d) Automatic temperature control of calibra-
tion fluid to 2 F, heated by electric
submersible heaters, and cooled by cold tap
water that flows through copper-finned
tubing in the reservoir.
(e) Transfer pump driven by a
1
/3 horsepower
motor at a rate of 150 GPH (9.5 liter/min)
at zero pressure, valves for controlling fuel
supply pressure and for suction testing of
injection pumps with integral transfer
pumps.
Page 1-2 Bacharach, Inc. Instruction 67-9268
Introduction Technician 7.5 & 10
1.2 Optional Accessories
(Not Supplied, see Section 5.5)
(a) Final Stage Filter and Gauge Kit: (Cus-
tomer installed) contains a 2 micron
spin-on type filter, hoses, 0100 psi (07 kg/
cm
2
) gauge and hardware.
(b) Pressure Lubrication System: Self con-
tained with motor driven lube oil supply
pump, reservoir, filter, hoses, and hard-
ware. This unit conveniently attaches to
the side of the Stand. Recommended for
pumps requiring pressurized lube oil
supply (AMBAC Model 100 and some
others).
(c) Portable High Pressure Timing Unit: Self
contained with motor driven high pressure
pump, reservoir, filter, hoses and hard-
ware. Required for timing and phasing
many in-line fuel injection pumps. For
more information, ask for Leaflet 1035.
1.1.4 Instrumentation
(a) Dual mode digital tachometer and stroke
counter: Automatic shift from tachometer
to stroke count; accuracy 1 RPM, 1 count.
(b) Compound pressure/vacuum gauge: Range
of 030" Hg (0-76 cm Hg) vacuum and
0100 psi (0-6.9 bar) pressure, both mea-
sured in the fuel supply line.
(c) Fuel inlet temperature gauge: Range of
40140 F (560 C).
(d) Eight collection graduates: 160 cc clear
acrylic pyramidal design with 0.5 cc subdi-
visions from 035 cc and 1 cc subdivisions
from 35160 cc.
Technician 7.5 & 10 Installation
Instruction 67-9268 Bacharach, Inc. Page 2-1
2.0 INSTALLATION
CA\TION
DO NOT apply electrical power or attempt
to operate the Technician Stand until all
steps in this section are completed.
2.1 Stand Preparation and Hook-up
The Technician Stand is shipped bolted to a pallet.
Remove these bolts; then use a lift truck to remove
the Stand from the pallet.
CA\TION
Take care that the forks of the lift truck do
not damage the four heavy-duty leveling
pads that protrude from beneath the Stand.
The Stand should be installed with sufficient
surrounding space on the sides and in the rear
(approximately 18 inches) to permit removal of its
access panels for periodic lubrication, maintenance
and/or inspection of the Stand.
2.1.1 Leveling
The Stand must be leveled to permit accurate
reading of the graduates. Four heavy-duty leveling
pads are provided, one in each corner of the frame.
Use a carpenters level, across and in parallel with
the pump mounting rails, and adjust the level jack
nuts to position the Stand level.
2.1.2 Electrical Hook-Up (Wiring)
Fuse the Stands circuit breaker wall panel to NEC
or local code. Table 2-1 will assist in selecting the
correct fuse size.
Tub!e 2-1. AC Pune! Iuse SIze
Stand Model / AC Input Amps (Time Delay Fuse)
Technican 7.5:
230 VAC, 3 ph., 60 Hz 35
460 VAC, 3 ph., 60 Hz 20
Technicain 10:
230 VAC, 3 ph., 60 Hz 45
Before attempting to wire the Technician Stand,
refer to Figure 2-2. Make certain to follow that
portion which refers to the exact voltage, phase
and frequency noted on the electrical nameplate
located at the rear of the Stand.
NOT: At this point, it is suggested to
remove the lower front and rear panels.
Referring to Table 2-2 and Figure 2-1, connect the
AC mains to terminal block TB1. Connect a ground
wire to the ground terminal. Note that wire size
(AWG) will vary with types of insulation, length of
conductors, etc. Consult NEC codes.
CA\TION
To prevent the possibility of burning out
the calibration fluid heaters with the fuel
reservoir empty, make certain that the
Calibration Fluid HEAT switch is off when
power is applied to the Stand.
Tub!e 2-2. AC MuIns Cuvvent und WIve SIze
Stund Vo!ts/Hz Motov 3 WIve SIze
No. HP Amps AWG
67-7683 460/60 7.5 18 10
67-7682 230/60 7.5 32 8
67-7696 230/60 10 40 8
2.2 Cold Water Hook-up
Two connecting points for water are provided at
the lower left rear of the Stand. Cold tap water
input should be connected to the upper bulkhead
adapter after installing a -NPT fitting to accom-
modate the cold water supply. A manual shutoff
valve is suggested for connection upstream of the
inlet fitting.
The cold water return connection (drain) is located
directly below the inlet bulkhead adapter and
requires a -NPT fitting for a drain hose connection.
CA\TION
Do not install any valves on the water
return drain line.
A hose (or pipe) " inside diameter (minimum)
should be provided for the unrestricted return of
cooling water to the drain. After the water inlet
Installation Technician 7.5 & 10
Page 2-2 Bacharach, Inc. Instruction 67-9268
and drain have been connected to the Stand (and
the water turned on), inspect all connections for
leaks. For operating details of the cooling system
refer to Section 3.4.
2.3 Filling Reservoir
Fill the calibration fluid reservoir (filling tube located in
the lower front panel) with approximately 13 U.S. gallons
(50 liters) of calibration fluid that meets SAE J967 (ISO
4113), see Section 5.1 for ordering a 15 gal. drum..
NOT: Use calibration fluid approved by
the fuel injection pump manufacturer only.
Most recommend SAE J967 (ISO 4113).
IIguve 2-1. !ectvIcu! CLussIs
2.4 Basic Accessories
The individual accessories supplied with each
Stand are listed in the Accessories Drawing
67-6323 enclosed with this Instruction.
Ground
Terminals
Main Power
Input Terminals
Fuses (F1 & F2)
460 VAC Only
Main Power
Cable Inlet
3 O I NPUT
FRONT VI EW
DANGER
HI GH VOLTAGE
\
TOP VI EW
(MC)
Motor
Control l er
(MC)
Motor
Control l er
(M1 )
Motor
Starter
(M1 )
(TC)
Temperature
Control er
(K1 )
Control
Rel ay
(GND)
Ground
Termi nal
Bl ock
(TB1 )
I nput
Termi nal
Bl ock
(TB2)
Termi nal
Bl ock
(BR1 & BR2)
(BR1 & BR2)
Braki ng
Resi stors
(TC)
Fuses
(F1 & F2)
Technician 7.5 & 10 Installation
Instruction 67-9268 Bacharach, Inc. Page 2-3
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Installation Technician 7.5 & 10
Page 2-4 Bacharach, Inc. Instruction 67-9268
IIguve 2-3. Cu!IbvutIon I!uId System
2 Optional Final Stage Filter and Gauge Kit (see Section 5.5) shown in enclosed area.
Technician 7.5 &10 Operation
Instruction 67-9268 Bacharach, Inc. Page 3-1
3.0 OPERATION
3.1 Control & Light Functions
The following is a description of the control and
light functions for the Technician Stand.
NOT: The numbers in the text refer to the
numbers on the corresponding figures.
3.1.1 Console Panel (Figure 3-1)
1. SUPPLY Switch (Calibration Fluid): Activates
the calibration fluid supply pump.
2. Calibration Fluid Indicator: Lit when the
SUPPLY switch is ON.
3. HEAT Switch (Calibration Fluid Heater):
Activates the calibration fluid automatic
temperature control system.
4. Calibration Fluid Heater Indicator: Lit when
the calibration fluid is being heated.
NOT: The Calibration Fluid Heater
indicator will cycle on and off during
normal operation.
5. TEMP. ADJ. Control (Temperature Adjust-
ment): Sets calibration fluid temperature in
the calibration fluid reservoir.
6. PUMP ROTATION Switch: Controls the
pumps direction of rotation.
7. STOP Button: Shuts down the main drive and
disconnects power to the controller. Once
activated, the button is locked, and must be
turned counterclockwise before it will unlock.
8. Stop Indicator: Lit while the main drive system
is in the STOP or unpowered state.
9. RUN Button: Starts the drive shaft rotating.
10. Run Indicator: Indicates that power is con-
nected to the main drive motor, and the drive
shaft is rotating.
11. SPEED Control: Sets speed (RPM) of the drive
shaft.
IIguve 3-1. Conso!e
2 4 8 10
1 3 5 6 7 9 11
DRIVE SYSTEM
SUPPLY
OFF OFF
HEAT
ON ON
TEMP ADJ.
CCW
PUMP ROTATION
CW
STOP
CALIBRATION FLUID
RUN SPEED
Operation Technician 7.5 & 10
Page 3-2 Bacharach, Inc. Instruction 67-9268
IIguve 3-3. By Puss & SLut OII Vu!ves
12 13
14 16
15
17
18 20
19 19
22
21
IIguve 3-4. TucL / Countev
IIguve 3-2. Ivont Pune!
TEMPERATURE
CAL. FLUID
SUPPLY RETURN
CAL. FLUID
VACUUM/PRESSURE
CAL. FLUID TO
FLOWMETER
TO FINAL
STAGE FILTER
CAL. FLUID FROM FINAL
STAGE FILTER RETURN
CALIBRATION FLUID SUPPLY
VACUUM/PRESSURE
TECHNICIAN 7.5
TEMPERATURE
CALIBRATION FLUID SUPPLY
Technician 7.5 &10 Operation
Instruction 67-9268 Bacharach, Inc. Page 3-3
3.1.2 Front Panel (Figure 3-2)
12. CALIBRATION FLUID SUPPLY VACUUM/
PRESSURE Indicator: A compound gauge that
indicates either positive or negative pressure
(vacuum) of the calibration fluid in the fuel
supply line (just behind the front panel).
13. CALIBRATION FLUID TEMPERATURE
Indicator: Displays the temperature of the
calibration fluid (just behind the front panel).
14. CAL. FLUID TO FLOWMETER: Measures the
calibration fluid return flow rate of rotary
distributor type pumps.
15. Graduates: Measures the fuel delivery of each
pump cylinder/outlet, which is routed from the
accumulator block.
16. TACH/COUNTER: A dual purpose unit consist-
ing of a digital tachometer and a preselectable
stroke counter. The stroke-cycle controls are
mounted on its front panel.
17. Flowmeter Input: Routes fluid to the
flowmeter.
18. CAL. FLUID SUPPLY Fitting: Provides
calibration fluid to the pump.
19. CAL. FLUID RETURN Fitting: Routes calibra-
tion fluid back to the calibration fluid reser-
voir.
20. TO/FROM FINAL STAGE FILTER Fittings:
Routes calibration fluid to and from the final
stage filter (Optional Accessory).
3.1.3 Side Panels (Figure 3-3)
21. Bypass Valve (Left hand side of Stand): Allows
operator to adjust Cal. Fluid Pressure.
22. Shut Off Valve (Left hand side of Stand):
Restricts or stops Cal. fluid flow to the pump.
23. DRAIN Valve (Right hand side of Stand,
Figure 3-6): Operating this lever drains the
graduates.
3.2 Tachometer / Counter Assembly
(Figure 3-4)
The TACH/COUNTER assembly in conjunction
with a magnetic pick-up and 120-tool gear provide
speed indication and revolution (stroke) counting.
The pick-up and gear are located in the rear of the
Stand. The gap between pick-up and gear is factory
set to .006 inches .001.
The TACH/COUNTER assembly is built into the
upper right-hand-front panel of the Stand. This
assembly processes the signals that it receives
from the magnetic pick-up assembly and indicates
the results on its 4-digit LED display. This unit
incorporates a 4-digit thumbwheel SELECT
STROKE switch for preselecting strokes. Indicator
lights show the assemblys mode of operation
either TACH MODE (tachometer) or COUNT
MODE (counter).
COUNT MODE is started by preselecting any
number of strokes in the SELECT STROKE
counter from 5 to 9999 and depressing the START
COUNT (draw) switch. If necessary, the count can
be stopped by the INTERRUPT (cancel) switch
after the draw cycle has begun.
The TACH/COUNTER assembly in its TACH
MODE continuously indicates drive shaft revolu-
tions per minute that is updated every 1 second.
3.3 Calibration Fluid System
(Figures 2-3 and 3-2)
This system consists of a fluid reservoir, waste
collector, motor-driven gear pump, SHUT OFF
VALVE, BY PASS VALVE, check valve, primary
filter, necessary plumbing and instrumentation.
Calibration fluid is drawn from a submerged filter
in the reservoir. Fluid is either supplied under
pressure to the injection pump, or drawn from the
reservoir under suction by the supply pump that is
mounted on the injection pump under test. If fluid
is to be supplied by the Stands supply pump to the
injection pump under test, then the one-way check
valve is closed. Manual adjustment of the calibra-
tion fluid pressure is done using the BY PASS
VALVE (Figure 3-3). Maximum available pressure
is approximately 75 psi.
Operation Technician 7.5 & 10
Page 3-4 Bacharach, Inc. Instruction 67-9268
If the calibration fluid is drawn out of the reservoir
with the Stands supply pump switched off, the
fluid passes through the check valve and out the
SHUT OFF VALVE to the injection pump under
test. In this mode, the BY PASS VALVE must be
closed (fully clockwise). Closing the SHUT OFF
VALVE completely or partially (Figure 3-3) will
stop or restrict the flow to the pump under test and
create vacuum upstream of the shut off valve. This
vacuum is indicated by the CALIBRATION FLUID
SUPPLY VACUUM/PRESSURE gauge. If re-
quired, calibration fluid can be circulated through
the final stage filter (an optional final stage filter
kit available for customer installation).
There are two CAL. FLUID RETURNs available
on the front panel. They are both routed directly to
the reservoir. The calibration fluid delivered by the
injection pump and injected into the accumulator
chambers is discharged into the graduate rack
housing and returns by gravity to the reservoir by
a separate line.
The reservoir is divided into three compartments
by baffles. This permits maximum mixing of hot
and cold calibration fluid and provides for stabi-
lized fuel temperature under all operating condi-
tions. The cooling compartment contains a coil of
finned tubing through which cold tap water flows
for cooling purposes when required. All fluid
returns from the pump and the test injectors are
diverted into this compartment.
The temperature of the fluid entering the reservoir
is generally higher than that in the reservoir. The
heating compartment contains four immersed
electrical heaters that provide heat to the calibra-
tion fluid when necessary. The thermostat is
mounted above the heaters. The main compart-
ment contains the submersible primary filter. The
three compartments are interconnected to permit
fluid flow from the cooling compartment past the
cooling coil into the heating compartment past the
heaters and thermostat into the main compart-
ment and out through the filter into the system.
A overheat thermostat is wall mounted on the
reservoir to detect possible overheating of the
calibration fluid. This could occur if the automatic
temperature controller malfunctions.
The temperature of the calibration fluid is mea-
sured in the supply piping (manifold) behind the
front panel and is indicated by the CALIBRATION
FLUID SUPPLY TEMPERATURE gauge mounted
in the upper right side of the front panel.
3.3.1 Calibration Fluid Temperature Control
(TEMP. ADJ.)
Heating of the calibration fluid is accomplished by
four 500 watt immersed electric heaters. Cooling is
provided by cold water flowing through finned
tubing immersed in the fuel reservoir. The thermo-
stat either switches on the heaters or admits cold
water for cooling. The thermostat is set at the
factory for a calibration fuel inlet temperature
range of 102106 F. Readjustment may be neces-
sary for specific pumps and particular test condi-
tions.
When adjusting the thermostat on the front
console, the injection pump should already be
warmed up and the whole system at operating
temperature. To maintain close control of the
calibration fluid temperature, it is recommended
that the supply pump operate during all tests,
whenever this is possible (open BY PASS VALVE
fully counterclockwise). Increased fuel flow
through the reservoir will increase the frequency
of the heating/cooling cycle and thereby supply
calibration fluid at a uniform temperature under
most operating conditions.
To readjust temperature setting after complete
warm-up, observe CALIBRATION FLUID SUP-
PLY TEMPERATURE gauge, then turn Calibra-
tion Fluid TEMP. ADJ. thermostat adjustment on
the front console CW to increase or CCW to de-
crease. Adjust by small increments only.
CA\TION
Allow 1015 minutes for calibration fluid
system to stabilize.
3.3.2 Front Panel Connections (Figure 3-2)
CAL. FLUID SUPPLY accepts
5
/8" ID hose (#10)
that is required for testing Cummins PT pumps.
For other applications, suitable reducers are
supplied for use with
1
/2" ID (#8) or
3
/8" ID (#6)
rubber or PVC hoses.
NOT: Use PVC hoses for supply under
very low pressures (below 10 psi) and
return. In all other cases use rubber hoses.
The two CAL. FLUID RETURNs accept
1
/2" ID (#8)
hoses and are provided for return of calibration
fluid to the reservoir. All connecting points, gauges
and controls are well identified by
Technician 7.5 &10 Operation
Instruction 67-9268 Bacharach, Inc. Page 3-5
nameplate and the calibration fluid system is
represented on the front and left-hand panel by
interconnecting lines and symbols.
3.3.3 Waste Tank
The drain pan is connected to a waste tank. By
preventing the spillage in the drain pan from
returning to the calibration fluid reservoir, the
possibility of contamination is greatly reduced.
Check the waste tank level periodically, and
discard the waste fluid as required.
The waste tank is located at the lower left rear of
the Stand and is accessible without removing the
rear panel. Remove drain hose and then slide tank
to rear for removal.
3.4 Water Cooling System
The cooling system will automatically shut off the
flow of cooling water when the power is off. This
system consists of a cooling coil, a solenoid valve,
and necessary plumbing. The cooling coil is in-
stalled in the calibration fluid reservoir.
The solenoid valve is a normally-closed, 2-way
valve. When energized, it permits cooling water to
flow through the calibration fluid reservoir and
then to the drain. This solenoid is energized when
the Calibration Fluid HEAT switch is ON, and
when the temperature control calls for cooling.
With the Calibration Fluid HEAT switch "ON", the
heaters or solenoid valve can be energized. When
the solenoid is energized, cooling water will flow
through the coil in the calibration fluid reservoir
and the heaters are shut-off.
When the temperature drops below the set point,
the thermostat provides a current path through
the normally closed safety thermostat, applying
current to the heaters. This causes the water
solenoid to de-energize and the heater light to
come ON. By this action, cooling water is blocked
from flowing through the reservoirs cooling coil,
thus allowing the calibration fluid temperature to
increase up to the set point previously established
at the TEMP. ADJ. potentiometer located on the
front panel.
3.5 Graduates
The Technician Stand contains a number of unique
features. The graduates are of clear molded plastic,
with 160 cc capacity. Graduations are every 1cc
except in the range from 035 where 0.5 cc gradua-
tions can be read. The pyramidal shape features a
high degree of readability. An aluminum spray
deflector located at the top of each graduate
diverts fluid to its back surface to minimize foam
accumulation.
The black vertical line on the rear wall of the
graduate provides a method of eliminating paral-
lax reading error.
3.5.1 Reading the Graduates (Figure 3-5)
A black vertical stripe painted on the back wall of
the plastic graduate serves to obtain an accurate
reading line for the correct fluid level. To find the
exact fluid level, move your eyes to the level of the
fluid and to a position at which the distance A is
at a minimum. At this position, the image (shown
in Figure 3-5) is formed.
The thin black horizontal line resulting from the
black stripe and fluid meniscus is the reading line.
Follow this line horizontally to the graduations
and read the volume in cubic centimeters (ccs).
IIguve 3-5. ReudIng Gvuduute
Operation Technician 7.5 & 10
Page 3-6 Bacharach, Inc. Instruction 67-9268
3.5.2 Draining the Graduates (Figure 3-6)
The graduate DRAIN lever is located on the upper
right side of the Stand. To drain fuel from the
graduates after a count, push in the graduate
DRAIN lever and move clockwise to the DRAIN
position. Release the lever to allow its notch to
engage the latch plate and hold the control lever in
the DRAIN position.
The graduates will continue to drain until the
control lever is released from the latch plate drain
position. Return the control lever to the FILL
position before starting the next count. The recom-
mended drain time is 30 to 35 seconds.
IIguve 3-6. Gvuduute vuIn Ievev
3.6 Accumulator Arm Assembly
(Figure 3-7)
Eight nozzle clamp post assemblies (and set
screws), used to assemble the accumulator for
operation, are packed in the parts bag.
1. Align flat spot on base of post with the
threaded hole on back of accumulator.
2. Slide each nozzle clamp post into holes pro-
vided for them on top of accumulator.
3. Place each set screw into a threaded hole on
the side of the accumulator block; then tighten
until it secures the nozzle clamp post.
The accumulator arm can be mounted on either
the right or left side of the Stands front panel
depending on the injection pumps application. If
the accumulator arm needs to be moved to the
other side of the front panel, slide the accumulator
arm out of its mounting tube and slide it into the
mounting tube on the opposite side. The accumula-
tor arm can be swung to move the accumulator out
of the way when necessary.
3.7 Flexible Anti-Backlash Coupling
(Refer to Sections 4.1.7 & 4.1.8
for Removal / Installation)
The coupling is secured to the Stand drive shaft by
a tapered-hub. The front (driving) flange is de-
signed for direct attachment to the pump driving
component (hub) without any backlash. The flange
also provides a pilot to ensure concentricity. A
drive Adapter (see Section 5.5) is available as an
optional accessory to make the flexible coupling
semirigid. The drive adapter is used only when it is
necessary to convert the flexible coupling for
driving pumps that require a tanged-type drive.
3.8 Correct Use of Alignment Gauge
For correct engagement of drive hub to the flexible
coupling, use the Alignment Gauge that is supplied
with the coupling.
1. Insert pins of the gauge between lamination
and flanges on each side.
2. When correct engagement exists the gauge will
drag slightly, exhibiting a slide-fit between
the pins on one side and the lamination and
flanges on the other. Note that excessive pull
or push on the lamination will permanently
distort them, requiring their replacement.
3. To avoid distorting or damaging the laminated
disc, the flexible coupling must always be
connected to an injection pump coupling before
the Stand is operated.
CA\TION
The rear flange lock nuts must be periodi-
cally checked for tightness (at least once per
month).
It is recommended that all bolts and nuts of the
coupling be periodically checked for tightness and
proper torque. There are approximately 6 Lamina-
tion (see Section 5.4 for part number) on each side
of the Flexible Coupling.
Technician 7.5 &10 Operation
Instruction 67-9268 Bacharach, Inc. Page 3-7
3.9 Typical Operating Sequence
Before performing the following steps, ensure that
the pump is mounted on the Stand according to
pump mounting diagrams or pump manufacturers
instructions (see Section 3.11), all necessary
connections have been made, and the pump is
ready for testing.
1. Set all switches on the Stand to their OFF or
fully CCW position.
2. Turn on water supply.
3. Turn on power to the Stand at the main
distribution panel.
4. Set main circuit breaker (CB1) on upper left
side to ON
5. Observe that the STOP (red) light is ON and
the RUN (amber) light is OFF.
6. Set the PUMP ROTATION switch to the
desired direction of pump rotation.
7. Turn BYPASS VALVE fully CCW (open).
8. Turn SHUTOFF VALVE to OPEN
9. Set the CALIBRATION FLUID SUPPLY and
HEAT switches to ON before running an
injection pump. Allow enough time for the
calibration fluid to reach operating tempera-
ture.
NOT: When calibration fluid reaches its
preset temperature, the HEAT ON lamp
will turn off. The calibration fluid system
will automatically run the heater elements
(HEAT lamp will be ON) or water will be
routed through the calibration fluid cool-
ing coil (HEAT lamp OFF) to maintain the
temperature preset by the TEMP ADJ.
control. The temperature is factory adjusted
to 104 2 F. In the event the injection
pump manufacturers instructions call for a
different temperature setting, use the
calibration fluid TEMP ADJ. to make
adjustments (reference Section 3.3.1).
10. Adjust the BYPASS VALVE to obtain the
desired calibration fluid supply pressure.
NOT: Negative pressure (vacuum)
generated by an injection pumps supply
pump (feed or transfer) can be read on the
compound gage after closing the SHUTOFF
VALVE.
11. Make sure that the STOP button is in the up
position. This control remains in the down
position once it has been depressed. The button
must be rotated counterclockwise in order for it
to release.
12. Depress and hold the RUN button until the
drive begins to turn.
13. Adjust the SPEED control to the desired RPM.
The RPM will be displayed on the TACH/
COUNTER.
14. Dial in the desired stroke count on the
SELECT STROKE thumb wheel switches.
15. Make sure the graduate FILL / DRAIN lever is
in the FILL position.
16. Depress the START COUNT switch to begin
the stroke count cycle. The graduate solenoid
energizes causing the graduates to begin
filling. The TACH/COUNTER will first display
the stroke count during the count cycle, and
then automatically return to its tachometer
mode.
NOT: The stroke count cycle may be
stopped at any time by depressing the
INTERRUPT switch.
17. After reading the graduates, move the gradu-
ate FILL / DRAIN lever to the DRAIN posi-
tion. Recommended drain time is 30 to 35sec-
onds.
Operation Technician 7.5 & 10
Page 3-8 Bacharach, Inc. Instruction 67-9268
3.10 Shutdown Procedure
1. Turn RPM control completely CCW (if not
already CCW).
2. Push the STOP Button.
3. Turn Cal. Fluid SUPPLY switch to OFF.
4. Turn Calibration Fluid HEAT switch to OFF.
5. Set main circuit breaker to OFF.
6. Turn OFF cold water supply.
3.11 Mounting Injection Pumps and
Test Injectors
Appendix A is a list of Pump Connection Dia-
grams available from Bacharach. These drawings
will assist the operator in mounting the fuel pumps
on the Stand. For exact pump test procedure and
specifications, refer to the pump manufacturers
service literature.
Refer to Appendix B for a listing what adapters,
spacers, bleed-off tubing, and clamps are needed to
mount and hold down the test injectors. Some
injectors require no adapters, while others may
require one or two in order to mount them into the
accumulator.
To install a nozzle:
1. Use appropriate nozzle holder adapters and
O Rings, as called for in Appendix B, on the
test injector.
2. Slide the injector into one of the accumulator
holes.
3. Slide the Nozzle Clamp under a set of posts on
the nozzle clamp post assembly so that the
ends rest on top of the injector. The notches on
top of the nozzle clamp should rest under the
posts.
4. Screw down the clamp screw assembly so that
it holds the nozzle tight.
IIguve 3-?. InJectov Instu!!utIon
NOZZLE CLAMP POST ASSY.
NOZZLE CLAMP
CLAMP SCREW ASSY.
NOZZLE HOLDER
ADAPTER
O-RING (05-5202)
15/16 ID x 1-3/16 OD
O-RING (05-5162)
1-3/16 ID x 1-5/8 OD
SET SCREWS
ACCUMULATOR
NOZZLE BLOCK
Technician 7.5 & 10 Maintenance & Troubleshooting
Instruction 67-9268 Bacharach, Inc. Page 4-1
4.0 MAINTENANCE &
TROUBLESHOOTING
4.1 Maintenance
CA\TION
Before performing any maintenance,
disconnect electrical power to the Stand at
the main AC distribution panel.
4.1.1 Belt Tensioning
The electric motor drive belt stretches in the first
few hours of operation. Check for proper tension at
the mid-position. Slack should not exceed
1
/2 inch
when compressed by hand.
To tighten electric motor drive belt:
1. Remove rear access panel
2. Loosen electric motor mounting bolts and
move complete assembly to tighten belt
3. Retighten mounting bolts to 10 lb-ft torque.
4.1.2 Lubrication (Figure 4-1)
Lubrication of the two main drive shaft bearings is
recommended after each 1000 hours of operation
or once a year, whichever occurs first. The follow-
ing lithium-base greases have been found to be
acceptable for this application.
Socony-Mobil Armvac-781
Texas Company Multifak 2 (E-P)-1990
Shell Oil Co. Alvania 2
To grease the main drive shaft bearings mounted
on the brackets, remove the rear access panels.
4.1.3 Calibration Fluid
The fluid should be replaced whenever any one of
the following events occur:
(a) After every 200 hours of operation.
(b) Viscosity increases to 3.2 cst (based on
SAE J967 (ISO 4113)) or more.
(c) Every three months or 200 pumps.
IIguve 4-1. MuIn vIve SLuIt Gveuse IIttIngs
Fill reservoir with 13 U.S. gallons (50 liters) of the
recommended calibration fluid. Most fuel injection
pump manufacturers recommend SAE J967 (ISO
4113) calibration fluid.
Replace primary filter every second fluid replace-
ment. To replace primary filter:
1. Drain calibration fluid reservoir with the
supply (transfer) pump.
2. Connect drain hoses to both drain valves.
3. Open both valves and drain residual calibra-
tion fluid in reservoir from both sides.
4. Remove screws securing the calibration fluid
reservoir to the frame.
5. Lower the calibrating reservoir to the floor.
6. Pull out all return hoses and remove the lid.
7. Loosen and remove the filter retainer and
slide out the filter.
8. Replace the filter with new filter and reas-
semble the reservoir in the reverse order.
Page 4-2 Bacharach, Inc. Instruction 67-9268
Maintenance & Troubleshooting Technician 7.5 & 10
Replace the optional final stage filter every second
fluid replacement. The final stage spin-on filter is
located behind the front panel. To replace filter,
use an automotive-type filter spanner wrench. For
correct part numbers of primary and final stage
filters, see Sections 5.1 and 5.5.
4.1.4 Graduates (Care/Cleaning)
Proper maintenance of the Graduates necessitates
periodic removal. Remove the rear access panel,
then proceed with the following:
1. Loosen the two socket head set screws in the
drain arm assembly.
2. Remove the drain arm from the drain rod.
3. Remove the upper right-hand side panel.
4. Remove two socket head cap screws from drain
arm mounting plate.
5. Remove graduate drain hose.
6. Pull the eight individual accumulator hoses from
front panel and drape them in the rear of Stand.
7. Remove two quick connects from graduate
solenoid.
8. Remove four hex nuts from graduate mounts
and remove complete assembly.
9. Remove the fill tube holder assembly by
removing the set screw and lock nut on the end
opposite the fill solenoid.
10. Remove three hex nuts holding the graduate
retainer bracket in place (located at the top of
graduates).
11. Slide retainer from the welded stud.
12. Graduates may now be serviced.
NOT: When cleaning graduates, a
detergent solution must be used. Do not
use solvents.
Reassemble in the opposite order of disassembly up
to Step 4, then proceed with the following to
properly set (bias) the graduate DRAIN lever.
1. Use vise grips on the drain rod assembly and
turn until the graduate drain valves are
raised to their maximum drain position as
viewed from the front.
2. Keep the drain rod assembly in this position,
then slide the drain lever mechanism onto the
end of the drain rod shaft.
3. Align the detent into the drain position and
secure drain arm to rod by tightening two set
screws.
4. Check results by shifting from DRAIN to
FILL position, then remove the vise grips.
4.1.5 Adjustment of Magnetic Pickup
(Figure 4-2)
The gap between the magnetic pickup and the 120
tooth gear is factory set to .006 inches.
The general indication that the gap setting is out
of tolerance, or that the magnetic pickup is defec-
tive and must either be reset or replaced is exem-
plified by an erratic RPM display on the TACH/
COUNTER. To adjust the magnetic pickup gap
setting, use the following procedure:
1. Turn main circuit breaker to OFF.
2. Remove the rear panel to gain access to the
magnetic pickup.
3. Loosen locknut on magnetic pickup body and
adjust until the gap between the top of the
teeth and the pickup is .006 in. (.001in.).
4. Manually rotate the flywheel one full turn
making certain that all teeth clear the pickup.
Use a dial indicator to check for concentricity
around the gear. If the encoder gear is eccen-
tric, loosen the three hex head cap screws
that secure the gear to the hub. Readjust the
gear and retighten the screws.
5. When proper gap setting is achieved, tighten
locknut, then recheck for concentricity.
6. Check Stand for correct RPM indication with
a hand held tachometer, especially at low
speeds (around 70 RPM). If RPM is incorrect,
refer to Section 4.2 Troubleshooting.
Technician 7.5 & 10 Maintenance & Troubleshooting
Instruction 67-9268 Bacharach, Inc. Page 4-3
IIguve 4-2. MugnetIc PIc -\p
4.1.6 Tach/Counter Replacement
No attempt should be made to repair this unit in
the field. If unit becomes inoperative with main
switch ON, check for tight electrical connections.
1. Use a voltmeter set on the appropriate range
and check that 230 VAC (approximate) is
present between Terminals 1 and 2 at rear of
tach/counter.
(a) If input voltage is present, it may indicate
that the unit is defective.
2. Another possible malfunction could be a
defective magnetic pick-up. Check the input
signal between Terminals 7 & 8 for
approximately 2.5 volts peak to peak.
(a) If signal is present, the tach/counter is
defective.
To replace this assembly:
1. RMOV POWR TO STAN.
2. Remove the rear access panel.
3. Use a
3
/16" socket wrench with extension and
remove the four hex nuts from the rear of the
tach/counter housing.
4. Disconnect and tag wiring after noting the
exact position of each connection.
5. Remove complete assembly by pulling for-
ward and out from the front panel.
NOT: Make certain to insulate all wiring
connections.
4.1.7 Removal of Flexible Coupling
(Figures 4-3 & 4-4)
IIguve 4-3. SLou!dev Bo!ts
1. Locate and remove the four shoulder bolts
from the rear flange
2. Remove the front flange and centering ring
assembly.
3. Remove the three hex head cap screws from
the tapered hub.
4. Install these screws into the tapped holes to
jack the hub from the rear flange.
5. Use the barring tool to facilitate hub removal,
while gradually tightening each screw in
sequence. Then slide hub off shaft.
6. If difficulty is encountered during hub
removal, wedge a screwdriver into hub slot to
relieve tension on the shaft. Caution: Excessive
force will split the hub.
Page 4-4 Bacharach, Inc. Instruction 67-9268
Maintenance & Troubleshooting Technician 7.5 & 10
IIguve 4-4. RemovIng Hub Ivom Reuv I!unge
7. Slide the rear flange and degree wheel
assembly off the shaft by pulling forward.
4.1.8 Flexible Coupling Installation
(Figures 4-5 thru 4-11)
1. Insert hub into tapered inside diameter of
rear driven flange.
2. Align the three bolt holes in hub with the
three tapped holes in the driven flange and
assemble loosely with three
1
/4-20 bolts and
lockwashers supplied with hub.
3. Slide the complete hub and rear flange
assembly over the drive shaft.
4. Slide hub and flange assembly along shaft
until 1-
3
/16" remains between endd of drive
shaft and hub.
NOT: Reference dimension of 1-
3
/16" is
designed to provide a final clearance of about
3
/4" between degree wheel and front panel
after hub is torqued to final specification.
5. Alternately tighten the three hex head cap
screws in 50, 25, 25 and 8 lb-in. increments in
rotational order. This will draw the driven
flange to the tapered hub uniformly. All three
cap screws will have a final torque of
108 lb-in. (Figure 4-6).
IIguve 4-5. I!e Ib!e Coup!Ing
IIguve 4-6. TIgLtenIng Hub Cup Scve s
NOT: When properly installed, the
tapered hub will remain stationary on the
Stand drive shaft and the drive flange will
be drawn into correct alignment with it.
The distance between front face of degree
wheel disc and degree wheel vernier should
be within
1
/64 when cap screws are
tightened to final torque.
6. With the rear flange and degree wheel se-
curely installed, check the front face of the
driven flange for perpendicularity using a dial
indicator against the top face of the flange
(Figure 4-7).
7. Install the dial indicator using a bracket
around one of the Stand rails.
Technician 7.5 & 10 Maintenance & Troubleshooting
Instruction 67-9268 Bacharach, Inc. Page 4-5
IIguve 4-?. CLec Ing Reuv I!unge Assemb!y
8. Bar coupling over one full turn and check that
deviation does not exceed 0.002 from the
perpendicular plane (wobble).
NOT: To prevent damage to the dial
indicator, make certain that the stem is
held as it passes over the milled slot in the
flange. The total misalignment must not
exceed 0.002 ". Should it exceed this, loosen
the three hex cap screws and retighten them
in the same manner as detailed in Step 5.
After retightening, check for misalignment.
IIguve 4-. P!ucIng Beve!ed WusLevs
Bet een IumInutIons & Reuv I!unce
9. Install four beveled washers over the shoulder
bolts protruding through laminated discs (Fig-
ure 4-8).
10. Refer to Figure 4-9. Horizontally align the
four shoulder bolts protruding through the
laminated discs with the holes in the rear
flange.
11. Place lock nuts (one at a time) into each of the
slots in the rear flange.
12. Tighten each bolt gradually until a final
torque of 13 lb-ft is achieved (Figure 4-10).
IIguve 4- . P!ucIng Ioc Nuts Into
S!ots on Reuv I!unge
IIguve 4-10. TIgLtenIng SLou!dev Bo!ts
Page 4-6 Bacharach, Inc. Instruction 67-9268
Maintenance & Troubleshooting Technician 7.5 & 10
CA\TION
Use Flexible Coupling Guard at all times
when flexible coupling is in operation.
Never operate Stand without flexible
coupling connected to a pump.
Make certain that there is 1" clearance
between the degree wheel and the coupling
guard. Failure to have sufficient clearance
could damage degree wheel (Figure 4-11).
IIguve 4-11. 1 Bet een WLee! & Guuvd
4.1.9 Motor Starter Overload Relay Adjustment
(Figure 4-12)
1. Find the operating volts located on the
nameplate of the Stand.
2. Locate the FLA (Full Load Amps) for the
corresponding voltage (step 1), which can be
found on the main drive motor controller
name plate.
3. The dial setting on the Motor Starter Over-
load Relay is equal to the FLA value.
IIguve 4-12. TypIcu! Motov Stuvtev ItL
Ovev!oud Re!uy
Technician 7.5 & 10 Maintenance & Troubleshooting
Instruction 67-9268 Bacharach, Inc. Page 4-7
4.2 Troubleshooting
Before attempting to troubleshoot, determine if the
problem is electrical and/or mechanical.
1. Electrical Problems
(a) Blown fuses or heaters, removing
power to one or more circuits.
(b) Relay contacts dirty/sticking or vibration
problems.
(c) Extreme line voltage drops (or transients).
(d) Faulty switches.
2. Mechanical Problems
(a) Broken, worn or loose belt.
(b) Loose parts due to vibration.
(c) Dirt/oil buildup on sensitive parts.
(d) Starved system due to clogged filter.
(e) Fluid leakage due to worn seals or loose
parts.
4.2.1 Electrical
Symptom PossIb!e Cuuse Remedy
1. Graduate fill solenoid does not energize Defective fill solenoid. Defective If 230 VAC absent between
when COUNT button is depressed. relay in tach/counter (SOL1)(TACH). Pins 3 & 4 when COUNT is
depressed, replace FILL
Test Points: solenoid SOL.1.
Terminal strip rear of tach/counter
Pins 3-4. Check for 230 VAC If 230 VAC present between 3
(Tolerance: 197-253 VAC). & 4 when COUNT is depressed,
replace defective tach/counter.
2. Motor Overload Relay trips. Improper Motor Overload Relay Readjust using Section 4.1.9.
setting (M1).
or
Improper line voltage. Verify the incoming line voltage
meets specifications.
or
Loss of a phase voltage. Investigate & correct problem.
or
Motor overload. Troubleshoot & correct problem.
or
Faulty motor (B1). Replace motor.
3. All systems function except Stop Button not reset. Rotate Stop Switch CCW to
main drive motor. allow button to return to the
up position (reset).
or
Stop Switch bad (SW5). Replace.
or
Motor starter bad (M1). Reset or replace.
or
Control Relay Bad (K1). Replace.
or
Motor controller bad (MC). Replace.
or
Run button bad (SW6). Replace.
Page 4-8 Bacharach, Inc. Instruction 67-9268
Maintenance & Troubleshooting Technician 7.5 & 10
4.2.1 Electrical (Cont.)
Symptom PossIb!e Cuuse Remedy
4. No calibration fluid temperature control. Low fluid level. Add fluid.
or
Temp. Sensor bad (S1). Replace.
or
Plug disconnected (P1). Reconnect.
or
Cooling solenoid open (SOL2). Replace
or
Overheat thermoswitch bad (TS1). Replace.
or
Temp. Controller failed (TC). Replace.
5. Motor and drive function at low and Braking resistor open (BR1 or BR2). Replace.
high speeds but trips out upon or
deceleration with light loads. Braking resistor wire(s) loose. Tighten.
6. Tach does not read RPM or Count. Magnetic pickup defective Replace
or Misadjusted. or Readjust.
7. Calibration fluid heating time slow. Heater(s) defective (HTR1-4). Replace.
or
Water solenoid valve stuck open Repair or replace.
(SOL2).
4.2.2 Mechanical
Symptom PossIb!e Cuuse Remedy
1. Air in Calibration Fluid Supply line. Low fluid level. Check and replace.
or
Loose connection(s) in system. Tighten as required.
or
Shut Off Valve leaky or defective. Repair or replace.
or
Supply pump shaft seal leaking. Repair or replace.
2. Excessive vibration when main drive Stand is not level and/or on rubber Make corrections.
motor is running. pads (under leveling screws).
3. Calibration temperature in reservoir No water supply. Troubleshoot.
not stable. or
Water supply valve stuck closed. Repair or replace.
or
Controls set wrong. Reset.
or
Calibration fluid pump inoperative. Troubleshoot.
Technician 7.5 & 10 Parts Lists & Diagrams
Instruction 67-9268 Bacharach, Inc. Page 5-1
5.0 PARTS LISTS
5.1 Belts, Filters, Etc.
Puvt escvIptIon ty/Stund
07-1614 Calibration Fluid Filter Cartridge - 10 micron Purolator 63104-02 or AC PF347................................... 1
05-2122 Main Drive Belt ......................................................................................................................................... 1
05-5107 Graduate 0-Ring S-7-3 (LT1) ................................................................................................................... 8
67-0094 Hose Assy. (Cal. Fluid Pump Inlet) ........................................................................................................... 1
67-4269 Hose Assy. (Cal. Fluid Pump Outlet) ........................................................................................................ 1
67-4517 Hose Assy. (Cal. Fluid Return to Reservoir) ............................................................................................. 3
67-4521 Hose Assy. (From Cal. Fluid Reservoir Outlet) ........................................................................................ 1
03-2912 Cal. Fluid Supply Pressure Gauge Connection (Plastic Line) ............................................................... 3 ft.
03-2913 Nylon Tubing
3
/8 0.D. ............................................................................................................................ 4 ft.
03-5108 Hose (Cal. Fluid Waste) ........................................................................................................................ 2 ft.
03-5109 Hose (Graduate Drain) ........................................................................................................................... 4 ft.
03-6063 Graduate Flexible Vinyl Tubing .............................................................................................................. 13
05-6304 Oil-Seal (For Cal. Fluid reservoir thermoswitch) ...................................................................................... 1
67-5598 Cal. Fluid (15 Gal. Drum) ......................................................................................................................... 1
5.2 Electrical Components
(Reference Pages 2-2 and 2-3 for Component Designations Shown in Parenthesis)
04-3585 Indicating Light (Amber) .......................................................................................................................... 3
04-3584 Indicating Light (Red) (LT2, LT3, LT4) .................................................................................................. 1
67-5426 Heater 240V 500W (Cal. Fluid Reservoir) (HTR1-HTR-4) .................................................................... 4
04-1311 Circuit Breaker (Mounted On Side Panel) (CB) ....................................................................................... 1
04-2719 Fuse (F1 & F2) 460 Volt Stand Only ........................................................................................................ 2
104-0348 Switch (ON/OFF) Cal. Oil Supply/Heat (SW2) ....................................................................................... 1
67-6142 Temperature Controller Assy. (TC) .......................................................................................................... 1
67-6244 Graduate Solenoid Assy. (TC) .................................................................................................................. 1
67-6141 Temperature Sensor (Cal. Fluid Reservoir) (S1) ...................................................................................... 1
67-6887 Supply Pump/Motor Assembly 230V/60 Hz/1 Phase (B2) ....................................................................... 1
03-4222 Solenoid Valve (Water) (SOL2) ............................................................................................................... 2
104-0084 Motor Starter (M1) 7.5 HP, 230 Volt Stand Only ..................................................................................... 1
104-0085 Motor Starter (M1) 7.5 HP, 460 Volt Stand Only ..................................................................................... 1
104-0098 Motor Starter (M1) 10 HP, 230 Volt Stand Only ...................................................................................... 1
04-4062 Main Drive Motor (B1) 7.5 HP, 230 and 460 Volt Stands Only .............................................................. 1
04-4120 Main Drive Motor (B1) 10 HP, 230 Volt Stand Only ............................................................................... 1
77-1122 Motor Controller (MC) 7.5 HP, 230 Volt Stand Only (Consult Factory for Programming Procedure) .. 1
77-1136 Motor Controller (MC) 7.5 HP, 460 Volt Stand Only (Consult Factory for Programming Procedure) ... 1
77-1130 Motor Controller (MC) 10 HP, 230 Volt Stand Only (Consult Factory for Programming Procedure) .... 1
04-5258 Control Relay (K1) .................................................................................................................................... 1
204-9411 Breaking Resistor (BR1 & BR2) 7.5 HP, 230 Volt Stand Only ................................................................ 2
204-9412 Breaking Resistor (BR1 & BR2) 7.5 HP, 460 Volt Stand Only ................................................................ 2
204-9413 Breaking Resistor (BR1 & BR2) 10 HP, 230 Volt Stand Only ................................................................. 2
04-9992 Arc Suppressor (Supply Pump Motor, Heaters, Water Solenoid, Control Relay) (RC2, RC3, RC4, RC5) ... 4
04-9993 Arc Suppressor (Motor Starter, Graduate Fill Solenoid) (RC1, RC6) ...................................................... 2
104-0357 Switch (Cal. Fluid Pump) (SW3) ............................................................................................................... 1
104-0336 Switch (Rotation) (SW4) ........................................................................................................................... 1
Page 5-2 Bacharach, Inc. Instruction 67-9268
Parts Lists & Diagrams Technician 7.5 & 10
104-0554 Contact Block, Normally Closed (Stop Button) (SW5) ............................................................................ 1
104-0555 Contact Block, Normally Open (Run Button) (SW6) ............................................................................... 2
104-0557 Button, Black (Run) *Does Not include Electrical Contact Block ........................................................... 1
104-0558 Button, Red (Stop) *Does Not include Electrical Contact Block.............................................................. 1
04-4872 Potentiometer (Speed Control) (R1) .......................................................................................................... 1
204-4593 Potentiometer 6 ohm, 4 watt W.W. (Temperature Adjust) (R2) .............................................................. 1
67-6170 Thermoswitch (Cal. Fluid Reservoir) (TS1) .............................................................................................. 1
5.3 Instruments
67-6204 Tachometer/Counter Assy. ........................................................................................................................ 1
67-6258 Magnetic Pick-up Assy. ............................................................................................................................ 1
67-6205 Temperature Gauge, 3
1
/2" Dial Size, Range 40-140F (5-60 Celsius) ................................................ 1
67-6206 Compound Gauge, 3
1
/2" Dial Size, Range 0-30" Hg, (0-76 cm Hg VAC), 0-100 psi., (0-7 kg/bar) ...... 1
67-6845 Sho-Rate 150 Flowmeter (Return Flow Meter) ..................................................................................... 1
5.4 Miscellaneous Parts
02-8201 Panel Fasteners (L-handle Type Latch) South Co. #61-20-107-11......................................................... 11
67-1120 Bulkhead Fitting (Cal. Fluid Inlet) ............................................................................................................ 1
03-2727 Bulkhead Fitting (Cal. Fluid Returns) ...................................................................................................... 2
06-8151 Leveling Pad,
1
/2-13 Stud (Fabcel #HD-300) ........................................................................................... 4
05-1405 Rear Drive Shaft Bearing, 1-
1
/2" ............................................................................................................... 1
67-6278 Front Drive Shaft Bearing, 1-
1
/2" (Modified) ........................................................................................... 1
67-5512 Graduate Assy. (Includes Valve Assy. 67-0346) ...................................................................................... 8
104-6532 Knob (Speed Control) ................................................................................................................................ 1
05-9519 Shock Mount (Electrical Chassis) ............................................................................................................. 4
03-4248 Shutoff Valve (Ball Valve
3
/4 FPT) ............................................................................................................ 1
67-2643 Gasket (Cal. Fluid Heaters) ....................................................................................................................... 1
67-0346 Graduate Valve Assy. ................................................................................................................................ 8
67-7702 Flexible Coupling Assy. ........................................................................................................................... 1
67-5433 Cooling Coil .............................................................................................................................................. 1
900-2654 Waste Can ................................................................................................................................................. 1
5.5 Optional Accessories
67-7610 Final Stage Filter and Gauge Kit ............................................................................................................... 1
07-1606 Final Stage Filter Element ......................................................................................................................... 1
67-7227 Pressure Lubrication System ..................................................................................................................... 1
72-7010 Portable High Pressure Timing Unit ......................................................................................................... 1
67-3541 Drive Adapter (Tanged)............................................................................................................................. 1
Technician 7.5 & 10 Appendix A
Instruction 67-9268 Bacharach, Inc. Page A-1
Listing of Pump, Mounting Diagrams for Bacharach
Calibrating Stands*
Dwg. No. Pump Male/Model/Application
67-9186C Ambac APE6BB (Mack)
67-9196C Ambac APE6BB, APE6Z
67-9185C Ambac APE8VBB, including
Short Housing and APE8VG
67-9078B Ambac APF1A, APF1B
67-9156D Ambac 100 - Navistar
77-9041D Ambac PSB12BT (MIL.)
67-9080B Ambac APE.A
67-9285C Ambac PSB6A (Mil.)
67-9410D Ambac 100 - Allis Chalmers
77-9070D Ambac PSU, 2/4 (M50)
67-9076B Bosch PES6P/Navistar DT817B,C
67-9077C Bosch PES8A75C/Navistar Trucks
67-9079B Bosch EP/VA - Navistar/Farm
67-9151C Bosch PES6P/John Deere
67-9129C Bosch PES6A/John Deere
67-9311D Bosch EP/VE - VW Rabbit
67-9439D Bosch PES4M/MB 190D
67-9424D Bosch PES6MW - Navistar (I)466
67-9451D Bosch EPVE/CDC
77-9083D Bosch P7100/Mack
67-9081B CAV NN (Mack/Scania)
67-9153C CAV Roto Diesel/John Deere
67-9276C CAV DP15
67-9305D CAV Roto Diesel/John Deere
67-9341D CAV-DPA
67-9428D CAV-DPA Case/Cummins
77-9121D CAV-DPC
77-9082D Cummins PT - Flowconsole
77-9085D Cummins PT - Flowmaster
* This is a complete list of Pump Mounting Diagrams.
Useonly those that apply to the Technician Stand.
Dwg. No. Pump Male/Model/Application
67-9134C Caterpillar 1 100
67-9139C Caterpillar 1673
67-9140C Caterpillar 1674
67-9141C Caterpillar 1693
67-9229D Caterpillar - Sleeve Metering 3208 (V8)
67-9228D Caterpillar - Sleeve Metering 3304, 3306
67-9238D Caterpillar 3406
67-9252D Caterpillar 3408/3412
67-9440D Caterpillar 3406 B New Scroll Type
67-9444D Caterpillar 3306 B New Scroll Type
67-9253C Diesel Kiki PES6A (Navistar/Nissan)
77-9142D Nippondenso NB(EP-9)
77-9086D Simms P5184/1
67-9125C Stanadyne DM/John Deere
67-9177C Stanadyne DM/Allis Chalmers
67-9176C Stanadyne DM/Allis Chalmers (Oiler &
Bracket Installation)
67-9287C Stanadyne DB-2 - GM 5.7L/V8, 4.3L/V6
67-9342D Stanadyne DB, DC
67-9399C Stanadyne DB2 - Navistar, 6.9L/V8,
7.3L/V8
67-9400C Stanadyne DB2 - Allis Chalmers 433
67-9401C Stanadyne DB2 - Onan 2.3L, 3.4L,
DB4 John Deere
67-9402C Stanadyne DB2 - Waukesha VRD220,
VRD330
67-9395C Stanadyne DB2 - GM 6.2L/V8
67-9445D Stanadyne DB2 - John Deere
77-9053C Stanadyne DB2 - Teledyne Continental
2.7L
APPENDIX A PUMP MOUNTING DIAGRAMS
Page A-2 Bacharach, Inc. Instruction 67-9268
Appendix A Technician 7.5 & 10
NOTS
Technician 7.5 & 10 Appendix B
Instruction 67-9268 Bacharach, Inc. Page B-1
APPENDIX B - INJECTOR ACCUMULATOR ACCESSORIES
The following is a list of injectors by manufacturer and the accumulator
accessories needed to run them on the Technician Stand. **
INJECTOR ACCUMULATOR ACCESSORIES APPLICATION TABLE
Test Injector Nozzle Nozzle Nozzle Notes
Holder Clamp
Mfg. Type/Size Adapter Adapter Holder
AMBAC DN12DI2, ADN8S2 67-6693* 77-0756*
& Bosch Orifice Type SAE/ISO " "
(all S Size)
AMBAC AKF130.................. " 77-0830 " Military
AKN212........ " 77-0770 77-0829
AMBAC Horizontal Inlet " 67-0449* 77-0756*
(MACK) Vertical Inlet " " "
Bar Stock " " "
AKN..(4 Valve Head) " 67-6245 "
Bosch Low Dead Volume 77-0625* " Mack (for
(1 688 901 101) P1700 pumps)
Low Dead Volume 67-6693* " EPVE-CDC
(1 688 901 027)
T Size "
Caterpillar IP 1715 67-6684 " Early Style
(Obsolete)
1U5500 (was 6V 9470) 77-0771 "
Zexel "T" Size (105780-8130) 77-0512 "
(Diesel KIKI) "Low Dead Vol.","S" Size 67-6693* "
* These parts can be found in the Basic Accessory Kit.
** This is a complete list of Injector Accumulator Accessories.
Use only those that apply to the Technician Stand.
Page B-2 Bacharach, Inc. Instruction 67-9268
Appendix B Technician 7.5 & 10
NOTS
Copyright 1997 Bacharach Inc.
WARRANTY
Bacharach, Inc., warrants to Buyer that at the time of delivery this product will be free from defects
in material and manufacture and will conform substantially to Bacharachs applicable specifica-
tions. Bacharachs liability and Buyers remedy under this warranty are limited to the repair or
replacement, at Bacharachs option, of this Product or parts thereof returned to Seller at the factory
of manufacture and shown to Bacharachs reasonable satisfaction to have been defective; provided
that written notice of the defect shall have been given by Buyer to Bacharach within one (1) year
after the date of this product by Bacharach.
Bacharach warrants to Buyer that it will convey good title to the Product. Bacharachs liability and
Buyers remedy under this warranty of title are limited to the removal of any title defects or, at the
election of Bacharach, to the replacement of this Product or parts thereof that are defective in title.
The warranty set forth in paragraph 1 does not apply to parts the Operating Instructions designate
as having a limited shelf-life or as being expended in normal use.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN
LIEU OF (i) ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT-
NESS FOR A PARTICULAR PURPOSE; AND (ii) ANY OBLIGATION, LIABILITY, RIGHT,
CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM
BACHARACHS NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall be
limited to those provided herein to the exclusion of any and all other remedies including, without
limitation incidental or consequential damages. No agreement varying or extending the foregoing
warranties, remedies or this limitation will be binding upon Bacharach unless in writing, signed
by a duly authorized officer of Bacharach.
A